Legal claims defining the scope of protection. Each claim is shown in both the original legal language and a plain English translation.
1. A failure detection apparatus for a photoreactive 3D printing system, the apparatus comprising: a light-emitting device configured to emit light into and along a plane of a membrane, the membrane being a bottom surface of a resin tub, wherein the light has a wavelength that is different from a photopolymerization wavelength of resin in the resin tub, and wherein the membrane is transparent to the wavelength of the light and to the photopolymerization wavelength; an imaging device oriented to capture an image of light emitted from the membrane; and a detection system in communication with the imaging device, the detection system being configured to detect a spatial disruption or a temporal disruption in the image.
This invention relates to failure detection in 3D printing systems that utilize photopolymerization, specifically addressing the problem of detecting defects or inconsistencies during the printing process before they propagate. The apparatus includes a light-emitting device designed to project light into and across a transparent membrane that forms the bottom surface of a resin tub. Crucially, this emitted light has a wavelength distinct from the photopolymerization wavelength used for curing the resin. The membrane itself is transparent to both wavelengths. An imaging device is positioned to capture the light emitted from this membrane. A detection system, connected to the imaging device, analyzes the captured image to identify any spatial or temporal disruptions. Such disruptions in the light pattern are indicative of issues like air bubbles, cured resin adhering to the membrane, or inconsistencies in the resin layer, which would otherwise lead to print failures.
2. The apparatus of claim 1 , wherein the spatial disruption is an area of non-uniformity in light intensity in the image.
This invention relates to an apparatus for detecting spatial disruptions in an image, particularly focusing on identifying areas of non-uniform light intensity. The apparatus is designed to analyze images to locate regions where light distribution deviates from expected uniformity, which can indicate defects, anomalies, or other irregularities in the captured scene. The primary application is in quality control, surveillance, or imaging systems where consistent light distribution is critical. The apparatus includes a light source that illuminates a target area, an imaging sensor to capture the reflected or transmitted light, and a processing unit that evaluates the image for spatial disruptions. The processing unit identifies regions where light intensity varies significantly from surrounding areas, flagging these as non-uniformities. These disruptions may arise from physical obstructions, surface irregularities, or environmental factors affecting light propagation. The apparatus may further include calibration mechanisms to establish baseline intensity levels, ensuring accurate detection of deviations. Advanced algorithms may be employed to differentiate between intentional variations (e.g., patterned lighting) and unintended disruptions (e.g., defects or contamination). The system can output alerts or adjust imaging parameters to mitigate the impact of detected non-uniformities. This technology is particularly useful in manufacturing, where consistent lighting is essential for defect detection, or in medical imaging, where light uniformity affects diagnostic accuracy. The apparatus enhances reliability by automating the detection of light intensity anomalies, reducing human error and improving process efficiency.
3. The apparatus of claim 1 , wherein: the imaging device captures a plurality of images at a plurality of time points; and the detection system detects the temporal disruption by identifying a change between the plurality of images.
This invention relates to an apparatus for detecting temporal disruptions in a monitored environment using an imaging device and a detection system. The apparatus captures multiple images at different time points to monitor changes over time. The detection system analyzes these images to identify temporal disruptions by detecting variations between them. The imaging device may be a camera or other sensor capable of capturing visual or non-visual data, while the detection system processes the data to recognize anomalies or deviations from expected patterns. The apparatus can be used in security, surveillance, industrial monitoring, or environmental sensing applications where detecting changes over time is critical. The system may include additional components, such as data storage or processing units, to enhance detection accuracy and reliability. The invention improves upon existing methods by providing a more robust and automated approach to temporal disruption detection, reducing the need for manual monitoring and increasing response efficiency.
4. The apparatus of claim 1 , wherein the light-emitting device is an infrared (IR) light source and the imaging device is an infrared camera.
This invention relates to an apparatus for detecting and analyzing objects using light-based imaging. The apparatus includes a light-emitting device that illuminates a target area and an imaging device that captures images of the illuminated area. The light-emitting device emits light in a specific wavelength range, and the imaging device is configured to detect and process this light to generate an image or data about the target area. The apparatus may be used for applications such as object detection, tracking, or identification, particularly in low-light or obscured environments. In one embodiment, the light-emitting device is an infrared (IR) light source, and the imaging device is an infrared camera. The IR light source emits infrared radiation, which is invisible to the human eye but detectable by the infrared camera. This configuration allows the apparatus to operate in conditions where visible light is insufficient or where objects need to be detected based on their thermal or reflective properties. The infrared camera captures images of the reflected or emitted infrared radiation, enabling the apparatus to analyze the target area for specific features, such as temperature variations, material composition, or object boundaries. This embodiment is particularly useful in applications like night vision, surveillance, industrial inspection, or medical imaging, where infrared imaging provides advantages over visible light imaging. The apparatus may also include additional components, such as processing units or filters, to enhance the accuracy and reliability of the imaging results.
5. The apparatus of claim 1 , further comprising a mirror, wherein: the mirror is reflective for the wavelength of the light from the light-emitting device and transmissive for the photopolymerization wavelength; the mirror is angled relative to the membrane and reflects the image to the imaging device; and the imaging device is off-axis from a central axis perpendicular to the plane of the membrane.
This invention relates to an optical apparatus for imaging and photopolymerization, addressing challenges in aligning imaging and curing processes in a compact system. The apparatus includes a light-emitting device that emits light at a specific wavelength, a membrane that interacts with this light, and an imaging device that captures an image of the membrane. A key feature is a mirror that is reflective for the light-emitting device's wavelength but transmissive for a photopolymerization wavelength, allowing simultaneous imaging and curing. The mirror is angled relative to the membrane, redirecting the image to the imaging device, which is positioned off-axis from a central axis perpendicular to the membrane's plane. This configuration enables efficient use of space while maintaining optical alignment between the imaging and curing functions. The apparatus is particularly useful in systems requiring precise imaging and photopolymerization, such as 3D printing or microfabrication, where compact and integrated designs are critical. The mirror's dual functionality and off-axis imaging device placement optimize performance without increasing system complexity.
6. A failure detection apparatus for a photoreactive 3D printing system, the apparatus comprising: a substrate below a membrane of a resin tub, wherein the membrane is a bottom surface of the resin tub; a light-emitting device configured to emit light into and along a plane of the substrate, wherein the light has a wavelength that is different from a photopolymerization wavelength of resin in the resin tub, and wherein the substrate is transparent to the wavelength of the light and to the photopolymerization wavelength; an imaging device oriented to capture an image of light emitted from the substrate; and a detection system in communication with the imaging device, the detection system being configured to detect a spatial disruption or a temporal disruption in the image.
A failure detection apparatus is designed for photoreactive 3D printing systems, specifically addressing the challenge of identifying defects or failures in the printing process. The apparatus monitors the integrity of a membrane at the bottom of a resin tub, which is critical for proper resin layer formation during printing. The system includes a transparent substrate positioned below the membrane, allowing light to pass through both the substrate and the membrane. A light-emitting device emits light at a wavelength distinct from the photopolymerization wavelength of the resin, ensuring the detection process does not interfere with the printing process. The light travels along the plane of the substrate, and any disruptions—such as tears, punctures, or delamination in the membrane—cause spatial or temporal variations in the emitted light. An imaging device captures these variations, and a detection system analyzes the captured images to identify and localize failures. This real-time monitoring enhances reliability by detecting membrane damage before it compromises print quality, reducing material waste and print failures. The apparatus is particularly useful in high-precision applications where membrane integrity is critical for consistent layer formation.
7. The apparatus of claim 6 , wherein the spatial disruption is an area of non-uniformity in light intensity in the image.
This invention relates to image processing systems that detect and analyze spatial disruptions in captured images. The problem addressed is identifying areas of non-uniform light intensity, which can indicate defects, anomalies, or other irregularities in the image. The apparatus includes an imaging device that captures an image of a target area and a processing unit that analyzes the image to detect spatial disruptions. These disruptions are defined as regions where light intensity varies significantly from surrounding areas, potentially indicating flaws or variations in the subject being imaged. The processing unit applies algorithms to quantify and map these intensity variations, enabling further analysis or corrective actions. The system may be used in quality control, surveillance, or medical imaging applications where detecting light intensity anomalies is critical. The apparatus ensures accurate identification of non-uniform regions by comparing local intensity values against a baseline or neighboring pixels, enhancing detection sensitivity and reducing false positives. This method improves upon traditional approaches by providing a more precise and automated way to assess image quality and detect irregularities.
8. The apparatus of claim 6 , wherein: the imaging device captures a plurality of images at a plurality of time points during a print run; and the detection system detects the temporal disruption by identifying a change between the plurality of images.
This invention relates to print quality monitoring systems designed to detect defects in printed materials during a production run. The system addresses the challenge of identifying temporal disruptions in the printing process, such as inconsistencies in ink application, substrate misalignment, or mechanical malfunctions, which can degrade print quality. The apparatus includes an imaging device that captures multiple images of the printed material at different time points throughout the print run. A detection system analyzes these images to identify changes or anomalies between them, indicating potential defects or disruptions in the printing process. The imaging device may be positioned to monitor specific areas of the printed material, such as registration marks or color patches, to ensure consistency. The detection system compares the captured images to reference images or predefined quality thresholds to determine if deviations exceed acceptable limits. If a disruption is detected, the system may trigger corrective actions, such as adjusting printer settings or halting production to prevent defective output. This approach enables real-time quality control, reducing waste and improving production efficiency. The system is particularly useful in high-speed printing environments where continuous monitoring is essential to maintain consistent output quality.
9. The apparatus of claim 6 , wherein: the imaging device captures i) a baseline image before or at a beginning of a print run, and ii) a second image during the print run; and the detection system detects the temporal disruption by comparing the second image to the baseline image.
This invention relates to an apparatus for detecting temporal disruptions in a printing process. The apparatus includes an imaging device and a detection system. The imaging device captures a baseline image before or at the start of a print run and a second image during the print run. The detection system analyzes these images by comparing the second image to the baseline image to identify any temporal disruptions in the printing process. The imaging device may be positioned to capture images of a print substrate, such as paper, as it moves through the printing system. The detection system processes the images to detect variations in print quality, alignment, or other defects that occur over time during the print run. The apparatus may also include a controller that adjusts printing parameters based on the detected disruptions to maintain consistent print quality. The imaging device may use optical sensors, cameras, or other imaging technologies to capture high-resolution images of the print substrate. The detection system may employ image processing algorithms to compare the baseline and second images, identifying differences that indicate disruptions in the printing process. This apparatus ensures that any deviations from the baseline print quality are detected and addressed promptly, improving overall print consistency and reducing waste.
10. The apparatus of claim 6 , further comprising a substrate holder, wherein: the light-emitting device is coupled to a surface of the substrate holder; and an edge of the substrate is supported by the substrate holder and placed adjacent to the light-emitting device.
This invention relates to a substrate processing apparatus designed to improve light exposure uniformity during semiconductor or display panel manufacturing. The apparatus addresses the challenge of uneven light distribution, which can lead to defects in photolithography or inspection processes. The system includes a light-emitting device positioned to direct light onto a substrate, such as a semiconductor wafer or glass panel, during processing. A substrate holder is integrated into the apparatus to securely position the substrate. The light-emitting device is directly coupled to a surface of the substrate holder, ensuring precise alignment. The substrate holder supports the substrate's edge while placing it adjacent to the light-emitting device, optimizing light exposure across the substrate's surface. This configuration minimizes shadowing and enhances uniformity, improving yield and quality in manufacturing processes. The apparatus may also include additional components, such as a light source driver or a cooling system, to further refine performance. The invention is particularly useful in high-precision applications where consistent light exposure is critical.
11. The apparatus of claim 6 , wherein the light-emitting device is an infrared (IR) light source and the imaging device is an infrared camera.
This invention relates to an apparatus for detecting and analyzing objects using infrared (IR) technology. The apparatus includes an IR light source and an IR camera to capture images of objects in low-visibility environments, such as darkness or fog. The IR light source illuminates the target area with infrared light, which is then reflected off objects and captured by the IR camera. The system processes these IR images to identify and analyze the objects, improving visibility and detection in conditions where visible light is insufficient. The apparatus may be used in applications like surveillance, security, or industrial inspections where traditional visible-light imaging fails. The IR light source and camera are designed to operate in tandem, ensuring accurate and reliable object detection by leveraging the unique properties of infrared light, which penetrates certain obstructions better than visible light. The system may also include additional components, such as processing units, to enhance image clarity and extract relevant data from the captured IR images. This technology addresses the challenge of detecting objects in low-light or obscured environments by utilizing infrared imaging, which provides better contrast and visibility compared to conventional visible-light cameras.
12. The apparatus of claim 6 , wherein the substrate is a glass sheet having a sheet plane with a size equal to or greater than the plane of the membrane.
This invention relates to an apparatus for handling or processing a membrane, particularly in applications where precise alignment or positioning of the membrane relative to a substrate is required. The problem addressed is ensuring accurate placement and stability of the membrane on the substrate, which is critical in fields such as semiconductor manufacturing, display technology, or flexible electronics. The apparatus includes a substrate holder designed to support a substrate, which in this case is a glass sheet. The glass sheet has a sheet plane with dimensions equal to or larger than the plane of the membrane, ensuring that the membrane can be fully accommodated on the substrate without overhang or misalignment. The substrate holder may include mechanisms for securing the glass sheet in place, such as clamps, vacuum chucks, or adhesive layers, to prevent movement during processing. The apparatus may also incorporate alignment features to ensure the membrane is positioned correctly relative to the substrate, such as optical sensors, fiducial markers, or mechanical guides. The invention may further include a membrane handling system, such as a robotic arm or a transfer mechanism, to place the membrane onto the substrate with precision. The apparatus may also have environmental controls, such as temperature or humidity regulation, to maintain optimal conditions for membrane-substrate bonding or processing. The use of a glass sheet as the substrate provides advantages such as transparency for optical inspection, rigidity for stability, and compatibility with various bonding or deposition processes. This design ensures that the membrane is securely and accurately positioned, improving yield and performance in manufacturing processes.
13. The apparatus of claim 6 , wherein the detection system is in communication with a control center of the photoreactive 3D printing system and is configured to send an alert to the control center when the spatial disruption or the temporal disruption is detected.
A photoreactive 3D printing system uses light to cure liquid resin into solid layers, building objects layer by layer. A key challenge is ensuring precise control over the curing process to maintain print quality and accuracy. Disruptions in the spatial or temporal distribution of light can lead to defects, such as incomplete curing or uneven layers. This invention addresses this problem by incorporating a detection system that monitors the light exposure during printing. The system identifies spatial disruptions, such as uneven light distribution across the build area, or temporal disruptions, such as fluctuations in light intensity over time. When such disruptions are detected, the system sends an alert to a central control unit, which can then adjust printing parameters or halt the process to prevent defects. The detection system may use sensors or imaging devices to measure light distribution and intensity in real time. The control center processes this data to determine whether the disruptions exceed acceptable thresholds. By providing immediate feedback, the system helps maintain consistent curing conditions, improving print quality and reducing material waste. This approach is particularly useful in high-precision applications where uniformity is critical.
14. The apparatus of claim 6 , further comprising a mirror, wherein: the mirror is reflective for the wavelength of the light of the light-emitting device and transmissive for the photopolymerization wavelength; the mirror is angled relative to the substrate and reflects the image to the imaging device; and the imaging device is off-axis from a central axis perpendicular to the plane of the substrate.
This invention relates to an apparatus for photopolymerization-based additive manufacturing, specifically addressing challenges in imaging and curing processes. The apparatus includes a light-emitting device that emits light at a specific wavelength to cure a photopolymer material on a substrate. A key issue in such systems is ensuring accurate imaging and alignment while maintaining efficient curing. The apparatus incorporates a mirror that is reflective for the light-emitting device's wavelength but transmissive for the photopolymerization wavelength. This mirror is positioned at an angle relative to the substrate, reflecting an image to an imaging device that is positioned off-axis from the central axis perpendicular to the substrate plane. This configuration allows for precise imaging while enabling the photopolymerization light to pass through the mirror to the substrate. The mirror's dual functionality—reflecting imaging light and transmitting curing light—optimizes the system's efficiency and accuracy. The off-axis imaging device improves alignment and reduces interference, enhancing the overall performance of the additive manufacturing process. This design is particularly useful in systems requiring high-resolution imaging and controlled curing, such as 3D printing or photolithography.
15. A method for detecting failures in a photoreactive 3D printing system, the method comprising: providing a light-emitting device configured to emit light into and along a plane of a substrate, the substrate mounted onto or below a resin tub, wherein the light has a wavelength that is different from a photopolymerization wavelength of resin in the resin tub, and wherein the substrate is transparent to the wavelength of the light and to the photopolymerization wavelength; providing an imaging device oriented to capture an image of light emitted from the substrate; and providing a detection system in communication with the imaging device, the detection system being configured to detect a spatial disruption or a temporal disruption in the image.
This invention relates to failure detection in photoreactive 3D printing systems, specifically those using resin-based additive manufacturing. The technology addresses the challenge of identifying defects or disruptions during the printing process, which can compromise part quality. The system employs a light-emitting device that emits light into and along a plane of a transparent substrate, such as a build plate or window, mounted onto or below a resin tub. The emitted light has a wavelength distinct from the photopolymerization wavelength of the resin, ensuring it does not interfere with the curing process. The substrate is transparent to both the emitted light and the photopolymerization wavelength, allowing unimpeded imaging. An imaging device captures images of the light emitted from the substrate, and a detection system analyzes these images for spatial or temporal disruptions. Spatial disruptions may indicate physical defects like cracks or misalignments, while temporal disruptions could signal issues like resin contamination or uneven curing. By monitoring these disruptions, the system can detect failures in real-time, enabling corrective actions to maintain print quality. The method enhances reliability in resin-based 3D printing by providing early detection of potential defects before they compromise the final part.
16. The method of claim 15 , wherein the substrate is a membrane serving as a bottom surface of the resin tub.
A method for manufacturing a resin tub involves using a substrate as the bottom surface of the tub. The substrate is a membrane, which provides structural support and defines the lower boundary of the tub during the manufacturing process. The membrane may be flexible or rigid, depending on the application, and is selected to ensure compatibility with the resin material used to form the tub. The membrane may also facilitate separation of the tub from the substrate after curing, ensuring a smooth and defect-free bottom surface. This approach improves manufacturing efficiency and product quality by providing a stable base for resin deposition and curing while allowing for easy removal of the finished tub. The membrane may be treated or coated to enhance adhesion or release properties, depending on the specific resin and manufacturing requirements. This method is particularly useful in additive manufacturing or molding processes where precise control over the tub's geometry and surface finish is critical. The membrane may also be reusable, reducing material waste and production costs. The method ensures consistent tub dimensions and surface quality, making it suitable for applications requiring high precision, such as medical devices, industrial containers, or consumer products.
17. The method of claim 15 , wherein providing the light-emitting device comprises mounting the light-emitting device at an edge of the substrate.
This invention relates to a method for fabricating a light-emitting device, specifically addressing the challenge of efficiently integrating light-emitting elements with a substrate to enhance performance and reliability. The method involves mounting a light-emitting device at the edge of a substrate, which improves light extraction efficiency and reduces thermal stress. The light-emitting device is positioned such that its active region is aligned with the substrate edge, minimizing internal reflections and maximizing light output. The substrate may be a semiconductor wafer or a flexible material, depending on the application. The mounting process ensures precise alignment and secure attachment, preventing misalignment or detachment during operation. This edge-mounted configuration also facilitates better heat dissipation, as the substrate edge provides a direct path for heat to escape, reducing thermal buildup. The method is particularly useful in applications requiring high brightness and thermal stability, such as displays, lighting systems, and optical sensors. By optimizing the placement of the light-emitting device, the invention improves overall device performance while maintaining structural integrity.
18. The method of claim 15 , further comprising: configuring the imaging device to capture a plurality of images at a plurality of time points; and configuring the detection system to detect the temporal disruption by identifying a change between the plurality of images.
This invention relates to a system for detecting temporal disruptions in an environment using an imaging device and a detection system. The problem addressed is the need to identify changes or disruptions over time in a monitored area, such as detecting motion, anomalies, or other temporal variations. The system includes an imaging device configured to capture multiple images at different time points. These images are analyzed by a detection system to identify changes between them, which indicates a temporal disruption. The detection system processes the sequence of images to compare them and determine if significant differences exist, such as movement, object appearance, or environmental changes. The method ensures that disruptions are detected by analyzing temporal variations rather than relying on a single snapshot. The imaging device may be a camera or sensor capable of capturing visual or other data over time. The detection system uses image processing techniques, such as frame differencing, optical flow, or machine learning models, to identify changes between consecutive or non-consecutive images. The system can be applied in surveillance, industrial monitoring, or autonomous navigation, where detecting temporal changes is critical for safety, security, or operational efficiency. The invention improves upon prior methods by providing a robust way to track and analyze disruptions over time, enhancing accuracy and reliability in dynamic environments.
19. The method of claim 15 , further comprising providing a mirror, wherein: the mirror is reflective for the wavelength of the light from the light-emitting device and transmissive for the photopolymerization wavelength; the mirror is angled relative to the substrate and reflects the image to the imaging device; and the imaging device is off-axis from a central axis perpendicular to the plane of the substrate.
This invention relates to a system for photopolymerization-based additive manufacturing, specifically addressing challenges in imaging and curing processes. The system includes a light-emitting device that emits light at a first wavelength to cure a photopolymer material on a substrate. An imaging device captures images of the photopolymerization process, and a mirror is used to reflect the image to the imaging device. The mirror is designed to be reflective at the light-emitting device's wavelength while being transmissive at the photopolymerization wavelength, allowing the curing light to pass through while reflecting the process image. The mirror is angled relative to the substrate to direct the image to the off-axis imaging device, which is positioned away from the central axis perpendicular to the substrate plane. This configuration enables real-time monitoring of the curing process without interfering with the curing light, improving accuracy and control in additive manufacturing. The system may also include a light source for the imaging device, which emits light at a third wavelength distinct from the first and photopolymerization wavelengths, further enhancing imaging clarity. The invention aims to optimize the balance between curing efficiency and imaging quality in photopolymerization-based additive manufacturing.
20. The method of claim 15 , wherein: the substrate is mounted below a membrane of the resin tub, the membrane serving as a bottom surface of the resin tub; and the method further comprises providing a second light-emitting device configured to emit light of a second wavelength into and along a plane of the membrane, the second wavelength being different from the wavelength of the light-emitting device that emits light into the substrate.
This invention relates to a system for curing resin in a tub using light, addressing the challenge of achieving uniform curing across the resin volume. The system includes a resin tub with a membrane serving as its bottom surface, and a substrate mounted below this membrane. A first light-emitting device emits light of a first wavelength into the substrate, which then transmits the light upward through the membrane into the resin. Additionally, a second light-emitting device emits light of a second wavelength, different from the first, into and along the plane of the membrane. This dual-wavelength approach ensures that light penetrates the resin from multiple directions and at different wavelengths, improving curing uniformity and efficiency. The membrane acts as a light-transmitting interface between the substrate and the resin, while the second light source provides lateral illumination to complement the vertical light from the substrate. This configuration is particularly useful in additive manufacturing or 3D printing processes where consistent resin curing is critical. The system may also include mechanisms to adjust the intensity or angle of the emitted light to optimize curing based on resin properties or desired print resolution.
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October 20, 2020
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